Product Descripons Process Plugins Soluons Soware ©2008-2016 Process Plugins Inc.
Plant and Equipment Performance Monitoring Soluons for any Industry
Choose On Site Soluons or Hosted Services ONSITE SOLUTIONS
Process Plugins provides full performance and condion monitoring installed onsite using the OSIso Asset Framework (AF)
The Process Plugins Advantage
Lowest cost soluon on the market
All engineering calculaons in plain view
Resides within OSIso technology
All soluons are user congurable aer inial training
Works with onsite OSIso technology so no new soware is required
Single windows service installed onsite with updates to the Units of Measure and the addion of AF templates
HOSTED SERVICES
Full performance and condion monitoring in a maer of days
Low monthly subscripon and fast deployment
No onsite soware installaon except OSIso Connected Services component
PI ProcessBooks supplied for onsite use
Geng started is easy:
End User Sends PI Tag List to Process Plugins
Process Plugins determines needed input and returns AF Structure for End User to place in AF Server
Plant and Equipment Performance Monitoring Soluons
Site publishes the input data to Process Plugins
Process Plugins subscribes to the input data
Calculaons veried for all purchased assets
Resulng full AF structure published to OSIso PI Cloud Connect
End User subscribes to Process Plugins and receives PI ProcessBooks
Reports viewable on any device provided
Performance Monitoring Soluons PPI-CCP-CTG-PRF: Process Plugins Combuson Gas Turbine Performance Monitor & Plant Heat Rates This module provides real -me compressor eciencies, expected generator capacity, and expected heat rates based upon compressor inlet temperature and humidity. This informaon can be useful in determining loss of turbine eciency or other problems. Curves are customizable and can be easily adjusted anyme
The Process Plugins Advantage
aerward. Expected values calculaons require the availability of appropriate curves (from the manufacturer or actual historical data). This tool makes it easy to idenfy problems with turbine performance early. This soluon also provides
No extra hardware required
Drag and drop templates
turbine condion since all environmental factors are removed and turbine
Weather templates for any locaon
performance is measured at the same base condions at all mes so any step
worldwide
change in the performance is easily detected. This module also includes real -me
corrected load and heat rate at base load which provides the best indicaon of
heat rates of each gas turbine as well as both net and gross heat rates of the combined cycle plant.
This informaon can be useful in determining loss of
turbine eciency or other problems.
PPI-CCP-CTG-FRC: Process Plugins Combuson Gas Turbine Weather-based Forecast Process Plugins regularly reads the weather forecast, and inserts hourly forecasted ambient condions into tables. Combuson gas turbine capacity and heat rate are forecasted using correcon curves and historic performance data. The forecast report is automacally emailed at any frequency desired (usually daily). Internet access is required for any associated computer for weather inputs. Process Plugins supports weather feeds from weather.gov (U.S. 7 -day by latude/longitude) and wunderground.com (Internaonal 10 -day by city name).
PPI-CCP-PLT-FRC: Process Plugins Combined Cycle Detailed Model with Weather-based Forecast A separate AF database is used for a detailed plant model.
Process Plugins
regularly reads the weather forecast, and inserts hourly forecasted ambient condions into the model. Any parameter may be included in the forecasted model report which is automacally emailed at any frequency desired (usually daily). Internet access is required for any associated computer for weather inputs. Process Plugins supports weather feeds from weather.gov (U.S. 7 -day by latude/ longitude) and wunderground.com (Internaonal 10 -day by city name).
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-GNL-HIS-BFL: Process Plugins Retroacve Calculaon BackFiller This tool performs performance calculaons using archived input data, and writes calculated results to corresponding mestamps retroacvely.
With KPIs (Key
Performance Indicators) retroacvely stored in PI -Tags, data retrieval is simple and robust.
The Process Plugins Advantage
The Calculaon Back-Filler comes with instrucons including a walk -
through tutorial so that future back -lling operaons may be easily performed in house. Process Innovaons recommends a minimum of 4 hours of onsite training before using the Calculaon Back -Filler.
User congurable with training
Robust scalability
PPI-CCP-CTG-ETP: Process Plugins Combuson Gas Turbine
Trigger events with new version of AF
Exhaust Temperature Prole Provides a real -me calculaon and polar plot of exhaust gas temperatures, and maps to originang combuson chamber. The exhaust swirl angle will be used to correct the combuson chamber posion so that each exhaust thermocouple points to the correct combuson chamber. This tool provides a visual map of exhaust temperatures, making it easy to idenfy uneven temperature distribuons, and the source combuson chamber associated with the given downstream thermocouples.
PPI-CCP-CTG-OCA: Process Plugins Combuson Gas Turbine Operaons Cost Analysis Operaonal parameters are compared to expected values and corresponding eects on unit heat rate (or eciency) and corresponding fuel costs/savings are calculated real-me and displayed. Manufacturer’s design curves are customized upon installaon and can be easily adjusted anyme aerward.
Parameters
include GT Inlet Filter Pressure Drop, GT Inlet Temperature, Compressor Secon Eciency and Cleanliness, Exhaust Temperature. This tool calculates real me nancial losses or savings (in $/hour) based upon given operaonal parameters in comparison to the target values. This tool is extremely valuable in idenfying means of immediate savings.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-CCP-CTG-OWA: Process Plugins Combuson Gas Turbine Oine Wash Advisor This tool determines the most economically advantageous me to perform an oine compressor wash. The advisor calculates this date/me using Maximum Net Prot Analysis.
The Process Plugins Advantage
PPI-CCP-CTG-AGA: Process Plugins Fuel Gas Orice Metering Flowrate
Ulizes PI ProcessBook, PI DataLink, PI WebParts, PI Coresight
This funcon is based upon American Gas Associaon (AGA) report numbers 3 & 8.
Enhancements ready for new version of AF with PI Analysis
compressibility (Z). The calculaons dened by AGA report #3 are implemented to
Equipment curves rendered in real me
(2) Base Compressibility, (3) Mass Flowrate, (4) Actual Volumetric Flowrate, and
The calculaons dened by AGA report #8 are implemented to calculate gas calculate real me fuel gas ow. The calculaon yields (1) Actual Compressibility, (5) Standard Volumetric Flowrate.
PPI-CCP-CHL-PRF: Process Plugins Chiller Performance Monitor & Advisor This soluon performs thermodynamic calculaons on the chiller coils, calculang the real me chiller duty, heat exchanger eecveness, heat transfer coecient, and air moisture removal rate. The chiller design specs are used to model the design condions for real me comparison. When incorporated in conjuncon with PPI-CCP-CTG-PRF (Combuson Gas Turbine Performance Monitor & Plant Heat Rates), chiller advisor will determine whether or not chiller operaon is benecial under current ambient condions. When incorporated in conjuncon with PPI-CCP-CTG-FRC (Combuson Gas Turbine Weather -based Forecast), chiller advisor will recommend chiller operaon based upon future ambient weather condions.
PPI-GNL-CCR-PRF:
Process
Plugins
Centrifugal
Compressor
Condion Monitor Compressor discharge pressure, work (brake horsepower) and eciency are calculated and ploed against the expected curves respecvely. Reference curves are scalable, dynamic, and adjust with compressor speed as appropriate. Real me calculaons include isentropic eciency and polytropic eciency.
The
graphic is very useful in visualizing real me compressor performance in
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) comparison to the reference curves. This tool makes it easy to idenfy problems early, such as degradaon in performance.
PPI-GNL-CCR-DSP: Process Plugins Centrifugal Compressor Map Display (using exisng KPIs) This is the PPI -GNL-CCR-PRF (above) with exisng KPI tags provided by the client.
The Process Plugins Advantage
PPI-GNL-RCR-PRF: Process Plugins Reciprocang Compressor Condion Monitor
Displays are element relave for easy management
Performance knowledge stored in AF
Monitor one piece of equipment or enre enterprise
Compressor stage and overall pressure raos, free air delivery (FAD), work and eciencies are calculated in real me. reference curves.
Calculated KPIs are ploed against
Real me calculaons include isothermal eciency and
volumetric eciency. The graphic is very useful in visualizing real me compressor performance in comparison to the reference curves. This tool makes it easy to idenfy problems early, such as degradaon in performance.
PPI-LNG-CTG-PRF: Process Plugins Combuson Gas Turbine Power Curves Provides a real-me power curves display of Corrected Power vs. Air Inlet Temperature. Power is ploed against design Full Load Output as well as PCD and WF curves. All other pernent KPIs are displayed as well as a trend of corrected and predicted power.
PPI-LNG-CTG-DSP: Process Plugins Combuson Gas Turbine P ower Curves Display (using exisng KPIs) This is the PPI -LNG-CTG-PRF (above) with exisng KPI tags provided by the client.
PPI-GNL-TEX-PRF: Process Plugins Turbo-Expander (Expansion Turbine) Condion Monitor The Compressor Condion Monitor (above) provides calculaons for the applicable sha load. Gas inlet and outlet condions are used to calculate the power extracted by the turbo -expander, applicable eciencies, and sha losses. These performance indicators are ploed real me with corresponding design curves. The display is a handy tool as it provides a visual display used to quickly idenfy potenal problems with the rotang equipment.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-CCP-HRS-PRF: Process Plugins HRSG Condion Monitor Provides real-me Heat Recovery Steam Generator (HRSG) eciency and eecveness (HP and LP as applicable) and tracks these parameters. NIST -JANAF tables are used to formulate ue gas enthalpies which are used to perform the necessary gas-side energy balances. This informaon can be useful in determining loss of HRSG integrity due to corrosion or other problems.
The Process Plugins Advantage
PPI-RCP-BLR-EFF: Process Plugins Boiler Eciency & Unit Heat Rates (Rankine Cycle Units)
Render any curve in PI ProcessBook
Element relave used for large quanty of equipment types
Gross turbine cycle heat rate is provided based upon the boiler’s steam -side heat
Render curves for variable frequency with real me views
is the most accurate way of ulmately calculang real -me coal ow and net unit
input to the turbine cycle. Boiler Eciency is calculated by the loss method, which heat rate.
PPI-RCP-UNT-OCA: Process Plugins Rankine Plant Operaons Cost Analysis Operaonal parameters are compared to expected values and corresponding eects on unit heat rate (or eciency) and corresponding fuel costs/savings are calculated real-me and displayed. Manufacturer’s design curves are customized upon installaon and can be easily adjusted anyme aerward.
Parameters
include Main Steam Pressure & Temperature, Reheat Temperature, Condenser Pressure, Cooling Tower Outlet Temperature (when Cooling Tower Performance is included), Feedwater Temperature, Hotwell Temperature, Aemperaon Spray Flows, & Auxiliary Staon Service Power. This tool calculates real me nancial losses or savings (in $/hour) based upon given operaonal parameters in comparison to the target values. This tool is extremely valuable in idenfying means of immediate savings.
PPI-RCP-BAH-PRF: Process Plugins Boiler & Air Heater Condion Monitor (Rankine Cycle Units) Boiler Losses are calculated real -me (in accordance with ASME PTC 4.1) and compared to expected losses and overall boiler eciency. Air heater exit gas temperature (corrected to zero leakage), gas side eciency, and x -rao are calculated and compared to expected real -me values. This soluon includes a custom display of the boiler side view and air heater when diagram is provided.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) Boiler Eciencies (Actual and Expected) and Steam Temperatures are trended to provide a visual display of Boiler Key Performance Indicators.
PPI-RCP-BLR-CLN: Process Plugins Boiler Cleanliness Monitor Each boiler secon is modeled and the overall heat transfer coecient is calculated in real me. Each secon’s cleanliness is calculated in real me and
The Process Plugins Advantage
Open source formulaons in AF
Ulizes OSIso visualizaons
All Engineering Knowledge in Plain View
displayed by a bar chart. This soluon includes a custom display of the boiler side view when diagram is provided.
PPI-RCP-BBM-PRF: Process Plugins Biomass Boiler Eciency & Performance Monitor Boiler eciency is calculated real-me and compared to expected boiler eciency. Performance indicators are ulized based on historical data.
PPI-RCP-BAX-PRF: Process Plugins Auxiliary Boiler Eciency & Condion Monitor Itemized Boiler Losses are calculated real -me (in accordance with ASME PTC 4.1) and compared to expected losses and overall boiler eciency. This soluon includes a custom display of the boiler side view when diagram is provided. Boiler Eciencies (Actual and Expected) and Steam Temperatures are trended to provide a visual display of Boiler Key Performance Indicators.
PPI-GNL-STB-PRF: Process Plugins Steam Turbine Condion Monitor This module provides real -me turbine secon eciencies and power output and tracks these parameters.
Formulaons are based upon ASME A Method for
Predicng the Performance of Steam Turbine Generators (by R.C. Spencer, K.C. Coon, C.N. Cannon).
Real me calculaons include actual and expected
eciencies of each individual steam turbine, steam power extracted from each individual turbine, and electrical and mechanical losses.
All steam turbine
leakages are calculated and accounted for. Calculaons are in accordance with ASME PTC 6/6s and ulize properes of water and steam calculated in accordance with the ASME 1997 formulaons. This informaon can be useful in determining loss of turbine eciency or other problems.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-GNL-GEN-RCP: Process Plugins Generator Reacve Capability The generator reacve capability curve is displayed in a dynamic real me display. This display is unique in that the hydrogen pressure (or temperature where applicable) D-curve accurately moves real -me with actual hydrogen pressure (or temperature) and reacve/real power is ploed within. The D -curve is ploed with extreme accuracy using true polar coordinates so that the enre limit curve is
The Process Plugins Advantage
Hosted services can have you monitoring in days Nocaons have complete access to the models for taking acon
displayed dynamically around the enre 180 degree plot. This tool provides a very handy visualizaon of real me operaon compared to the limitaons.
PPI-GNL-WCC-PRF: Process Plugins Water Cooled Condenser Condion Monitor The condenser is modeled to predict pressure, temperature dierence (TTD), and
With full plant conguraon we can provide a “What If” model
cleanliness. These parameters are compared real -me to the corresponding actual
Templates for wide array of Wind Trubine types
indicate problems with condenser operaon or physical condion, which oen has
condions which are also calculated.
Dierences in expected results could
a substanal impact on plant heat rate.
PPI-GNL-CTR-PRF: Process Plugins Cooling Tower Condion Monitor Provides real-me expected cooling tower outlet temperature based upon wet bulb temperature and range (circ -water temperature rise). The Process Plugins toolset provides the calculaon of wet bulb temperature from humidity or dew point as necessary. This informaon can be useful in determining problems with cooling tower operaon or physical condion.
Curves are customized upon
installaon and can be easily adjusted anyme aerward. Expected values calculaons require the availability of appropriate curves (from the manufacturer or actual historical data).
PPI-GNL-CWP-ADV: Process Plugins Circ Water Pump Advisor This module provides real -me opmal Circulang Pump conguraon in order to minimize the unit’s (or enre plant’s) net heat rate.
This tool requires the
Condenser Performance package in order to determine the eects of various pump conguraons on condenser pressure, and resultant eects on turbine cycle heat rate. Circ water pump power consumpon is considered in determining the opmal CW pump conguraon for the real -me given condions.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-GNL-PMP-PRF: Process Plugins Pump Condion Monitor Pump head and eciency are calculated and ploed against the expected curves respecvely. Reference curves are scalable, dynamic, and adjust with pump speed as appropriate. Real me calculaons include driver/pump set eciency, pump eciency, performance factor, sucon head, NPSH, discharge head, and total head. The graphic is very useful in visualizing real me pump performance in
The Process Plugins Advantage
comparison to the reference curves. This tool makes it easy to idenfy problems early, such as degradaon in performance.
Web Based Reports available on any device Report conguraon in AF can be viewed anywhere on any device
PPI-GNL-PMP-DSP: Process Plugins Pump Condion Monitor (using exisng KPIs) This is the PPI -GNL-PMP-PRF (above) with exisng KPI tags provided by the client.
PPI-RCP-FWH-PRF: Process Plugins Feedwater Heater Condion Monitor Each feedwater heater is modeled to predict the feedwater outlet temperature, terminal temperature dierence (TTD), drain cooler approach (DCA), and steam extracon ow. These parameters are compared real -me to the corresponding actual condions which are also calculated. Dierences in expected results could indicate problems with heater operaon or physical condion.
PPI-GNL-DEA-PRF: Process Plugins Deaerator Condion Monitor The Deaerator is monitored to predict the feedwater outlet temperature, terminal temperature dierence (TTD), and steam extracon ow. These parameters are compared real-me to the corresponding actual condions which are also calculated. Dierences in expected results could indicate problems with deaerator operaon or physical condion.
PPI-GNL-HEX-PRF: Process Plugins Heat Exchanger Condion Monitor This soluon performs thermodynamic calculaons on the heat exchanger tubes/ ns/coils, calculang the real me duty, heat exchanger eecveness, heat transfer coecient, and uid ows as appropriate. The heat exchanger design specs are used to model the design condions for real me comparison.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) PPI-GNL-BLO-PRF: Process Plugins Blower Condion Monitor Blower eciency and total pressure are calculated and ploed against the expected curves. Reference curves are scalable, dynamic, and adjust with blower speed as appropriate. Real me calculaons include uid power, driver/fan set eciency, blower eciency, and total pressure. The graphic is very useful in visualizing real me blower performance in comparison to the reference curves.
The Process Plugins Advantage
This tool makes it easy to idenfy problems early, such as degradaon in performance.
Templates for all types of wind turbines
PPI-WND-WTB-PRF: Process Plugins Wind Turbine Condion and
Forecast wind and generaon soluons for world wide locaons
Assets Monitor Wind asset parameters are organized by Region, Site, Turbine, and Component within PI-AF. A master display is provided with drill-down capabilies to support ve levels of hierarchy: Execuve, Regional, Site, Turbine, and Component screens. Calculaons include Availability, Capacity Factors, and totalizing funcons. Turbine status is monitored for any gear boxes, generator and overall performance issues. Real me performance of the turbine compared to expected performance is displayed within Process Book of the PI WebParts.
PPI-WND-WTB-FRC: Process Plugins Wind Turbine Site Capacity Forecast Based upon weather forecast at the site locaon, wind turbine generator capacity is predicted into the future. Curves are customized upon installaon and can be easily adjusted anyme aerward. Internet access is required for an associated computer or the Analysis Framework server for weather inputs. Expected values calculaons require the availability of appropriate curves (from the manufacturer or actual historical data). Process Plugins supports weather feeds from weather.gov
(U.S.
7 -day
by
latude/longitude)
and
wunderground.com
(Internaonal 10 -day by city name).
PPI-COK-BAT-TOT: Process Plugins Coking Baery and Oven Monitor and Totalizer This soluon calculates and totalizes key parameters of the coking baeries and ovens. Calculaons include, but are not limited to daily, (today and yesterday), weekly, monthly, and yearly NTE (not to exceed) event counters of high and low
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) temperatures, damper posions, charge weights and control limits, feed rates, & emissions.
PPI-GEN-DST-PRF:
Process
Plugins
Disllaon/Evaporaon/
Desalinaon Plant Monitor This soluon monitors the performance of the disllaon/evaporaon/
The Process Plugins Advantage
desalinaon plant. Fresh water producon and energy consumpon are analyzed to provide real me indicaon of plant performance compared to design values. This soluon also includes real -me mass balance reconciliaon of supply water,
Soluons for pulp and paper or any air cooled condenser
fresh water, and waste water.
Monitor and alert on chemistry excursions with monitoring and OSIso Nocaons
PPI-PAP-PLP-PRF: Process Plugins Pulp Line Condion Monitor This soluon monitors the performance of the pulp line by comparing real -me drive motor power, water consumpon, and chemical and bleaching agent consumpon to design and/or expected historical values.
PPI-GNL-ACC-ADV: Process Plugins Air Cooled Condenser Fan Advisor This module provides real -me opmal ACC Fan conguraon in order to minimize the unit’s (or enre plant’s) net heat rate.
ACC Fan power consumpon is
considered in determining the opmal ACC Fan conguraon for the real -me given condions.
PPI-GNL-DRM-CHM: Process Plugins Drum Chemistry Monitor Real me chemistry indicaons are displayed and ploed against the expected curves. Reference curves are scalable and dynamic where appropriate. Real me visualizaons include silica and caon conducvity vs. drum pressure, and pH vs phosphate. The graphic is very useful in visualizing real me chemistry status in comparison to the reference curves. PI Nocaons is leveraged to provide email alerts to any anomaly in chemistry requiring aenon.
PPI-GNL-REG-PRF: Process Plugins Reciprocang Engine Generator Performance Monitor & Plant Heat Rates This module provides real -me expected generator capacity, and expected heat rates based upon manufacturer specicaons. This informaon can be useful in
Plant and Equipment Performance Monitoring Soluons
Process Plugins Soluons Soware©
Performance Monitoring Soluons (cont.) determining loss of machine eciency or other problems.
Curves are
customizable and can be easily adjusted anyme aerward. Expected values calculaons require the availability of appropriate curves (from the manufacturer or actual historical data).
This tool makes it easy to idenfy problems with
machine performance early.
PPI-ODS-WEB-CON: Web Connector
The Process Plugins Advantage
Connect diverse data sources to your PI server with a single applicaon installed on or with access to one or more data sources.
The Process Plugins Web
Web Connector allows access without addional hardware or VPN infrastructure
Connector allows you to send data from any internet connected machine to your
Ulizes OSIso Web Services or PI Web API
company and start connecng all of your data sources without addional onsite
Capture remote data without expensive infrastructure Data not in your PI Archive server easily montored with our hosted services
PI server in a safe secure manner using web services and industry standard SSL transport. Let Process Innovaons help you congure PI Web Services at your hardware or VPN infrastructure.
PPI-ODS-WEB-DTL: Web Data Link Connector This product provides similar funconality as the OSIso PI DataLink product but uses the PI Web Services to retrieve the data into Excel. Internal or external to your company this can be used to pull data directly into Excel. With the PI Web Services congured on your network and using industry standard SSL transport even outside enes can extract data directly from your PI server based on permissions you choose for data access.
PPI-ODS-WEB-ERP: Process Plugins ERP Connector Since most ERP System Web Services are too complex for OSIso Nocaons, Process Plugins provides a user congurable tool that will help you build a web service that will then communicate to the ERP system web service. This soluon creates OSIso Nocaons with a Web Service Delivery Channel to your ERP (Maximo, SAP etc.) which can trigger direct delivery to your system from the PI System. This soluon can be used to congure preventave maintenance triggers in the PI System and have the Nocaons trigger when maintenance is needed. For example, you can congure an urgent request for work with a Nocaon triggered on high vibraon, high temperature etc. automacally trigger a work order for the work.
Plant and Equipment Performance Monitoring Soluons
The connector will then
From data source to decision, Process Plugins Soluons So ware gives you everything you need all built inside the OSIso infrastructure so your investment is secure using all of your exisng tools.
Plant and Equipment Performance Monitoring Soluons
Process Plugins Inc. 2519 South Shields Street #166 Fort Collins, Colorado 80526 For more informaon or to schedule a demonstraon: Phone 1 -970-266-8551
[email protected] hp://www.ProcessPlugins.com